Our goal of this research is to fabricate near-net-shape isotropic (Nd) 2Fe 14B-based (NdFeB) bonded magnets using a three dimensional printing process to compete with conventional injection molding techniques used for bonded magnets. Additive manufacturing minimizes the waste of critical materials and allows for the creation of complex shapes and sizes. The binder jetting process works similarly to an inkjet printer. A print-head passes over a bed of NdFeB powder and deposits a polymer binding agent to bind the layer of particles together. The bound powder is then coated with another layer of powder, building the desired shape in successivemore » layers of bonded powder. Upon completion, the green part and surrounding powders are placed in an oven at temperatures between 100°C and 150°C for 4–6 h to cure the binder. After curing, the excess powder can be brushed away to reveal the completed “green” part. Green magnet parts were then infiltrated with a clear urethane resin to achieve the measured density of the magnet of 3.47 g/cm 3 close to 46% relative to the NdFeB single crystal density of 7.6 g/cm 3. Magnetic measurements indicate that there is no degradation in the magnetic properties. In conclusion, this study provides a new pathway for preparing near-net-shape bonded magnets for various magnetic applications.« less

Grain boundary diffusion of a Pr 3(Co,Cu) eutectic alloy has been performed for coercivity enhancement on Nd-lean Nd 10Fe 84B 6 nanocrystalline ribbons. The coercivity increases from 0.5 T to 2.5 T after 6 h of infiltration at 600 °C. High resolution electron microscopy and energy dispersive X-ray spectroscopy show that the excess α-Fe present in the initial samples diminishes during infiltration, giving rise to the formation of a Rare Earth-rich RE-Fe inter-boundary phase and a layer of (Nd,Pr) 2Fe 14B close to the surface of the hard magnetic grains. Such a microstructure favours the coercivity by increasing the nucleationmore » field for reversal magnetization and providing magnetically isolated/decoupled hard grains.« less

WC-Co was made via binder jet additive manufacturing of tungsten carbide followed by melt infiltration with a Co-WC infiltrant. The goal of the study was to achieve fully densified parts in near-net shape with minimal shrinkage while keeping the Co content low. The exact amount of infiltrant was determined in order to fully densify with minimum shrinkage based on the actual volume taken up by WC powder in the preform based on theoretical density, the bounding volume of prints after shrinkage, and the volume from the infiltrant. The eutectic nature of the infiltrant enabled melting at much lower temperature comparedmore » to the melting temperature of pure Co. The density, microstructure, grain size, hardness, and fracture toughness were characterized. The shrinkage and net shaping were assessed with light scans. A detailed look at the fracture mechanics was assessed. Here, this approach achieved highly dense WC-Co parts in net-shape with Co vol% of near 29 (Co wt% ~19), density of 96.2% theoretical, hardness of 8.34 GPa, grain size of 7.7 μm, magnetic saturation of 0.5 T, room temperature thermal conductivity of 125 W/mK, and fracture toughness of 24.7 = MPa·m 1/2.« less